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Foamed composites and methods for making same

a composite material and composition technology, applied in the field of foamed compositions and compositions, can solve the problems of wood members suffering from cost problems, wood used in these applications, and under certain circumstances, and achieve the effects of reducing the amount or degree of cooling needed to slow down or terminate foaming, effective control, and convenient practi

Inactive Publication Date: 2005-05-10
HUGHES PROCESSING +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

"The present invention provides foamable compositions with improved properties such as durability, weatherability, and the ability to control foaming. The foamable compositions have a polymeric component and an encapsulated foaming component that work together to provide a controlled foaming process. The encapsulated foaming component may include a polymer component and a blowing agent. The foamable compositions may also contain a wood component to give the resulting foamed composition a wood-like appearance. The methods for making the foamable compositions involve providing a polymeric component, adding an encapsulated foaming component, and optionally adding a wood component."

Problems solved by technology

However, the wood used in these applications, under certain circumstances, can have problems.
Wood can deteriorate due to the effect of fungus and insect attack.
Also, wood members suffer from cost problems related to the availability of wood suitable for construction purposes.
Furthermore, wood requires substantial upkeep comprising painting or staining.
However, the degree of foaming in these thermoplastics presently cannot be well controlled.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

examples 1 and 2

[0079]The following formulations for forming polymeric components are prepared by combining the listed ingredients:

[0080]

Example 1Example 2wt %wt %Uncross-linked, linear75.8666.88acrylonitrile / styrenecopolymers(1)Cross-linked n-butyl acrylate / 22.3831.59graft methyl (meth)acrylate copolymer(2)Lubricant(3)1.151.00Stabilizer(4)0.150.13Light stabilizer(4)0.300.27Antioxidant(4)0.150.13(1)Sold by Bayer under the trademark Lustran 31 (contains about 23% by weight of acrylonitrile). (2)Sold by Rohm & Haas Co. under the trademark Acryloid KM334, n-butyl acrylate / butylene glycol diacrylate / methyl methacrylate / alkylacrylate (3)Sold by Struktol Corporation under the trademark TR-251, metal stearate / amide composition effective as lubricant. (4)Well known, commercially available component.

examples 3 and 4

[0081]The following formulations for forming polymeric components are prepared by combining the listed ingredients. Wood particles are also added to the formulation.

[0082]

Example 3Example 4wt %wt %Uncross-linked, linear69.561.6acrylonitrile / styrenecopolymers(1)Cross-linked n-butyl acrylate / 20.428.6graft methyl (meth)acrylate copolymer(2)Wood Particles(5)8.08.0Lubricant(3)1.51.3Stabilizer(4)0.150.13Light stabilizer(4)0.300.27Antioxidant(4)0.150.13(1), (2), (3) and (4)are shown in Examples 1 and 2. (5)100 U.S. Mesh pine wood flour.

[0083]Each of these formulations of Example 1 to 4 is thoroughly mixed at elevated temperatures of about 400° F.-450° F. (which is the melt temperature range of the copolymer combinations in these formulations) to form a substantially uniform, extrudable composition.

examples 5 to 8

[0084]Each of the samples that is produced in Examples 1 to 4 is successfully formed into pellets using a Cincinnati Milacron Model CM-80 conical twin screw extruder and a

[0085]Beringer Water Ring Pelletizer. In each, the following conditions are employed.

[0086]

Barrel Zone 1325° F.Barrel Zone 2325° F.Barrel Zone 3365° F.Barrel Zone 4365° F.Adaptor Zone 1365° F.Adaptor Zone 2365° F.Screenchanger365 ofZone 3Die Zone 4375 ofDie Zone 5375 ofScrew Oil350 ofMotor, RPM2000Motor Load, amps 110

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Abstract

Foamable compositions are provided including a polymeric component, an encapsulated foaming component in an amount effective in foaming the foamable composition and a wood component in an amount effective as a filler in a foamed composition obtained from the foamable composition. Foamed compositions and methods of producing foamed positions are also provided.

Description

BACKGROUND OF THE INVENTION[0001]The present invention relates to foamable compositions, foamed compositions and methods of making foamed compositions. In particular, the invention relates to foamable polymeric compositions including encapsulated blowing agents, foamed polymeric compositions and methods for making foamed polymeric compositions.[0002]Conventional residential, commercial and industrial architecture commonly involve the use of structural and nonstructural components in the assembly of useful articles. These components are often made from wood. Wood can be milled into shaped structural components such as sized lumber, trim, post and beam. Additionally, wood can be used to form structural components that can be assembled with glass to form door and window units.[0003]Lumber, trim, post, beam and assembled profiles or articles (or units) comprising wood have obvious utility and are well adapted for many uses in many residential or commercial installations. However, the wo...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): C08J9/00C08J9/32B29C44/12
CPCB29C44/12C08J9/32C08J9/0085C08J2203/22
Inventor JOHNSON, LOWELL FRANKHUGHES, RODERICK E.
Owner HUGHES PROCESSING